The present invention generally relates to magnetic recording media and methods of fabricating the same, and more particularly to a magnetic recording medium having a lubricant layer and a method of fabricating such a magnetic recording medium.
In magnetic recording media typified by magnetic disks, there are increased demands to further improve the recording density year by year. In order to satisfy such demands for high magnetic recording density, a flying height of a head from a magnetic disk surface has become approximately 10 nm which is extremely small. For this reason, a margin of the head flying height has also become small, and the head is more likely to make contact with the magnetic disk surface at the time of the recording or reproduction. In addition, in the head having a Dynamic Flying Height (DFH) function, the head flying height constantly varies depending on a projecting amount of an element part, and the flying height has decreased to the order of several nm.
The general magnetic disk employing the horizontal or perpendicular magnetic recording has a stacked structure having an underlayer, a recording layer, a protection layer and a lubricant layer that are successively stacked on a substrate. The lubricant layer that is provided at a surface portion of the magnetic disk is formed by coating the lubricant layer on the protection layer by a dipping process, for example, and thereafter subjecting the lubricant layer to a baking process to improve the molecular orientation of the lubricant layer. As a result, the lubricant layer on the side of the protection layer is formed by a bond layer, while the lubricant layer at the surface portion of the magnetic disk is formed by a mobile layer. The bond layer is strongly bonded to the protection layer, which is made of Diamond-Like Carbon (DLC), for example, by the baking process. For this reason, the bond layer is unlikely to separate or become peeled off from the protection layer even when the head makes contact with the magnetic disk surface. In addition, the film thickness of the bond layer increases due to the baking process. On the other hand, the mobile layer easily separates or becomes peeled off when the head makes contact with the magnetic disk surface, and the separated mobile layer is likely to adhere on the head. This is because, unlike the bond layer, the mobile layer is the surface portion of the lubricant layer that is not strongly bonded to the protection layer, and the surface of the mobile layer has undulations and is not an ideal planar (or flat) surface. In other words, the head having the extremely small head flying height may easily make contact with convex portions of the undulations at the surface of the mobile layer. However, the mobile layer is essential in order to secure the durability of the magnetic disk.
The so-called Head Disk Interference (HDI) occurs due to the above described contact between the head and the mobile layer. The HDI also occurs when foreign particles exist on the mobile layer, and the separated portions of the mobile layer may become such foreign particles.
Various magnetic recording media provided with a lubricant layer, and methods of fabricating magnetic recording media have been proposed, including Japanese Laid-Open Patent Publications No. 3-153645, No. 2006-12215 and No. 2006-48801, and International Application Publication WO01/001403.
The film thickness of the mobile layer of the lubricant layer is desirably thin from the point of view of suppressing the adsorption to the head, but the durability of the magnetic recording medium deteriorates if no mobile layer is provided. For this reason, although it is desirable to control the film thickness of the mobile layer to a thin value, it was difficult to stably control the film thickness of the mobile layer to a thin value according to the conventional fabricating method.
Hence, in the conventional magnetic recording media, the mobile layer forming the surface portion of the lubricant layer is easily adsorbed on the head, and the tendency of the mobile layer becoming adsorbed on the head became more notable as the head flying height decreased.
Accordingly, it is an object in one aspect of the invention to provide a magnetic recording medium and a method of fabricating the same, in which adsorption of a mobile layer forming a surface portion of a lubricant layer onto a head is suppressed.
One aspect of the present invention is to provide a magnetic recording medium comprising a substrate; and a recording layer, a protection layer and a lubricant layer that are stacked above the substrate, wherein the lubricant layer includes a bond layer in contact with the protection layer, and a mobile layer at a surface of the magnetic recording medium and having a bonding strength weaker than that of the bond layer with respect to the protection layer, and a height of convex portions at a surface portion of the mobile layer is approximately 0.3 nm or less.
According to one aspect of the present invention, there is provided a method of fabricating a magnetic recording medium comprising forming a lubricant layer on a protection layer of the magnetic recording medium, so that the lubricant layer includes a bond layer in contact with the protection layer, and a mobile layer at a surface of the magnetic recording medium and having a bonding strength weaker than that of the bond layer with respect to the protection layer; and rinsing the lubricant layer on the protection layer by a rinsing process in order to reduce a film thickness of the mobile layer.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
Preferred embodiments of the present invention will be described with reference to the accompanying drawings.
According to one aspect of the present invention, adsorption of a mobile layer forming a surface portion of a lubricant layer onto a head is suppressed.
A description will now be given of a magnetic recording medium and a method of fabricating the same, in each embodiment according to the present invention.
In one embodiment of the present invention, the film thickness of the mobile layer 13B of the lubricant layer 13 is decreased by a rinsing process in order to improve the flatness of the surface of the mobile layer 13B. Hence, it is possible to reduce the undulations at the surface of the mobile layer 13B, and stably control the film thickness of the mobile layer 13B. For this reason, even if the head flying height of a head 16 decreases, it is possible to suppress adsorption of the mobile layer 13B forming the surface portion of the lubricant layer 13 onto the head 16. Furthermore, because the film thickness of the mobile layer 13B can be stably controlled to a thin value, it is possible to positively secure the durability of the magnetic recording medium 20.
Of course, the structure between the recording layer 11 and the substrate 9 is not limited to the structure illustrated in
As may be seen from
Next, a description will be given of the method of fabricating the magnetic recording medium 20 in the case where the magnetic recording medium 20 is the magnetic disk.
A step ST1 carries out a dipping process to coat the lubricant layer 13 on the protection layer 12. In this dipping process, the magnetic disk having the structure up to the protection layer 12 already formed on the substrate 9 thereof by the preceding processes is dipped into a processing chamber 31 which contains a lubricant made of a fluoric material, in a direction X1, and is then pulled out from the processing chamber 31 in a direction X2. The fluoric material may be Fomblin Z-Tetraol, Z-Dol or AM3001 respectively manufactured by Solvay Solexis, for example. The wait time (or dip time) of the magnetic disk within the processing chamber 31 was controlled in the step ST1 so that the final mobile layer ratio becomes approximately 5% to approximately 40%.
A step ST2 carries out a known baking process to heat the magnetic disk which is coated with the lubricant layer 13, within a backing chamber 32, in order to improve the molecular orientation of the lubricant layer 13. As a result, the bond layer 13A was formed in the lubricant layer 13 on the side of the protection layer 12, while the mobile layer 13B was formed in the lubricant layer 13 at the surface portion of the magnetic disk. The bond layer 13A is strongly bonded on the protection layer 12 by the baking process. In this example, the steps ST1 and ST2 form a lubricant forming process to form the lubricant layer 13.
A step ST3 carries out a rinsing process to decrease the film thickness of the mobile layer 13B and improve the flatness of the surface of the mobile layer 13B. In this rinsing process, the magnetic disk having the structure up to the lubricant layer 13 already formed on the substrate 9 thereof and subjected to the baking process described above is dipped into a rinsing chamber 33 which contains a rinsing liquid made of a fluoric solvent or pure water, in a direction X3, and is then pulled out from the rinsing chamber 33 in a direction X4. As a result, the undulations at the surface of the mobile layer 13B are reduced, and the film thickness of the mobile layer 13B is stably controlled. The fluoric solvent may be FC77/FC3255/HFE730 manufactured by 3M Company, Vertrel-XF manufactured by DuPont or, H-Galden manufactured by Solvay Solexis, for example. After the step ST3 which forms the rinsing process, the magnetic disk is subjected to a test or the like in a next process. Of course, a single chamber (or tank) may be used as the processing chamber 31 and the rinsing chamber 33.
In this embodiment, the rinsing liquid within the rinsing chamber 33 was maintained in a range of approximately 20° C. to approximately 25° C. in order to suppress volatilization of the fluoric solvent in the case where the fluoric solvent is used as the rinsing liquid. In addition, in order not to be affected by the surface wave of the rinsing liquid when the magnetic disk is dipped into the rinsing liquid, the wait time (or dip time) of the magnetic disk within the rinsing chamber 33 was set in a range of approximately 10 seconds to approximately 30 seconds. Moreover, in order not to be affected by the surface wave of the rinsing liquid when the magnetic disk is pulled out of the rinsing liquid, the pull speed was set in a range of approximately 50 mm/sec to approximately 200 mm/sec, where “mm/sec” denotes millimeters per second. Further, during the wait time (or dip time) of the magnetic disk within the rinsing chamber 33, the rinsing process was promoted by ultrasonic oscillation.
Accordingly, a magnetic disk having the bond layer 13A with a film thickness of approximately 0.6 nm to approximately 1.2 nm and the mobile layer 13B with a film thickness of approximately 0.1 nm to approximately 0.5 nm was fabricated. According to experiments conducted by the present inventors, it was confirmed that in order to suppress the total film thickness of the lubricant layer 13 to approximately 1.7 nm or less, the mobile layer ratio is desirably approximately 5% to approximately 30%. It was also confirmed that in order to suppress the height of the convex portions of the undulations at the surface of the mobile layer 13B to approximately 0.3 nm or less, for example, the mobile layer ratio is more desirably approximately 5% to approximately 10%.
For example, the magnetic disk having the structure up to the protection layer 12 already formed on the substrate 9 thereof by the preceding processes is simultaneously subjected to a lubricant forming process and a rinsing process by use of a single processing chamber 41. The processing chamber 41 contains a lubricant 42 made of a fluoric material and a rinsing liquid 43. Hence, when a dipping process is carried out to dip the magnetic disk into the processing chamber 41 in a direction X5 and then to pull out the magnetic disk in a direction X6, the lubricant layer 13 is coated on the protection layer 12 at the time of dipping the magnetic disk, and the rinsing process is carried out with respect to the lubricant layer 13 at the time of pulling out the magnetic disk. The fluoric material used for the lubricant 42 and the fluoric solvent or pure water used for the rinsing liquid 43 may be the same as those used in the embodiment described above. According to this embodiment, the magnetic disk can be fabricated in a short time at a low cost when compared to the embodiment described above.
In the case of the embodiment illustrated in
On the other hand,
In other words, according to each of the embodiments described above, it was confirmed that the adsorption of the mobile layer 13B, forming the surface portion of the lubricant layer 13, onto the head 16 is suppressed even when the head flying height of the head 16 decreases. In addition, because the film thickness of the mobile layer 13B can be stably controlled to a thin value, it was also confirmed that the durability of the magnetic disk is positively secured.
Therefore, embodiments of the present invention are applicable to various magnetic storage apparatuses, such as magnetic disk drives, in which the head flying height is extremely small.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contribute by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification related to a showing of the superiority and inferiority of the invention. Although the embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
This application is a continuation application filed under 35 U.S.C. 111(a) claiming the benefit under 35 U.S.C. 120 and 365(c) of a PCT International Application No. PCT/JP2007/053431 filed Feb. 23, 2007, in the Japanese Patent Office, the disclosure of which is hereby incorporated by reference.
Number | Date | Country | |
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Parent | PCT/JP2007/053431 | Feb 2007 | US |
Child | 12488188 | US |